Battery Module Injection-Molded Plastic Sheath Encapsulation
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Solution Overview
Problem
Existing methods for producing high-capacity battery modules, particularly lithium-ion systems, are costly and inefficient due to elaborate processes involving multiple component packaging, leading to heavy and expensive products.
Innovation Solution
A method involving the encapsulation of battery cells and connectors in a common, one-piece plastic sheath through injection-molding, eliminating the need for additional housings and reducing production complexity, while allowing for reduced weight and improved insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate housings are used for packaging battery cells and connectors, then adequate fixing, sealing and insulation of components is achieved, but production costs increase, production efficiency decreases, and the final product becomes heavier
Solution Approach 1:
The patent combines multiple separate packaging housings into a single integrated housing that accommodates both battery cells and connectors. This single housing performs the functions of fixing, sealing, and insulation for all components simultaneously, eliminating the need for multiple separate packaging layers and reducing assembly complexity while maintaining protective functions.
2Reliability
If multiple separate housings and packaging layers are used, then component protection is improved, but the total weight of the battery module increases
Solution Approach 1:
The patent merges multiple protective housings into a single housing structure, thereby reducing the total material used for packaging while maintaining comprehensive protection for all components. This single housing replaces what would otherwise require multiple separate housings, directly reducing the overall weight of the battery module.
3Stability of the object's composition
If multiple separate housings and assembly steps are used, then component fixation is achieved, but the number of assembly steps and production time increase
Solution Approach 1:
The patent integrates the fixation functions for battery cells and connectors into a single housing assembly process. Instead of requiring separate assembly steps for different housings, the single housing is designed to accommodate and secure all components in one assembly operation, thereby reducing the number of production steps and improving manufacturing efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach lowers production costs, reduces weight, and enhances insulation by encapsulating all components in a single plastic sheath, minimizing assembly errors and leakages, and allows for the use of lighter, corrosion-resistant plastics, thereby improving the efficiency and performance of battery modules.
Implementation Method 1
packaging all of the battery cells of the battery module or system in a common, optionally one-piece, plastic sheath by encapsulation injection-molding
Data Source
AI summary
A method for producing battery modules or battery systems having a plurality of battery cells includes interconnecting and optionally arranging the battery cells with cell connectors to form the battery module or battery system architecture. The method also includes fitting the battery module or battery system with terminals and packaging all the battery cells of the battery module or system in a common plastic sheath by injection molding, so that the battery cells and cell connectors of the battery module or system are surrounded substantially completely by the plastic sheath. The battery module terminals or battery system terminals remain accessible from outside. A battery module or battery system can be produced in accordance with the method of the disclosure.